The amount of active CCD is limited. Opening the HMI is using some of the available CCD.
Closing the HMI is releasing the CCD again.
When you repeatedly open and close the browser, the CCD can still be in use and getting into the limitation.
(There is a delay for releasing the CCD when closing the connection).
„If a client wants to subscribe to new data variables while no more CCDs are available, a message “CCD exceeded!” will appear and there will be no communication with these data variables.“
„If a client disconnects from the visu (e.g. browser gets closed), it will take some time until the browser session expires and the CCDs from this client become available once again (session timeout of the scada server: 2 min.).

How to solve a CCD exceeded?
Close alle open browser connection and wait for >2 min.
Now you should be able to open the HMI without error message.

How to prevent a CCD exceeded?
Don’t open the HMI in several browser simultaneously.
Don’t repeatedly open and close the HMI in short time.
Don’t repeatedly press reload the HMI in short time.

The height of the tooling should be between – 0.2 and + 0.2 mm, shown on the handle/shaft underneath the tooling. If needed, move the height of welding roller again, till the roundness of the can is sufficient.

Reset the upper pendulum rollerhead:

Angle: Normally not necessary, as long as nobody touched/dis-adjusted red marked screws on the support).

Horizontal axle: Make sure that the height of the pendulum axle is parallel to the welding roller axle. Use for this setting a precise level, and level the shaft of the pendulum rollerhead according the level of the welder, or do it according the manual, using the delivered gauge set.

Position of exit conveyor:

Use the delivered stainless steel gauge, put it into the tooling, and let both belts (of the OHC) touch that gauge slightly.

Make sure the OHC is parallel to its basic plate on the lift

Position of diabolo center between 1–3 mm before lower weld roll center.

Conical overlap:

Too much overlap in the beginning: Move tooling foward, 0.5 mm/move

Too much overlap in the end: Move the tooling backwards, 0.5 mm/move

Can gap tolerance shall be within 0.5 mm:

Can gap on aerosol: 2.0 – 3.0 mm

Can gap on beverage/food: 1.5 . 2.5 mm

Belt for pendulum rollerhead should be tensioned tight.

Belt for profiling unit must be tight, before and after the profiling unit

Check the overlap only by an internal diameter gauge, with a dial indicator to read result. Diameter tolerance should not be higher 0.1 mm.

Check the tin flow after the upper, and after the lower welding roller on the copper wire.

Do not accept anything but the center

Check the overtravel of the can body:

Move the pusher finger to the very front, and measure the distance from the pusher plate, until the center of the lower welding roller.

Now deduct this measure from your cutted tin plate height and you know how many mm the tin plate gets pushed over the center of the lower welding roller.Attention: If you have spatters on the beginning of the can, which show backwards, move the transport carriage backwards. Do that over the can height setting on the touch screen.

Rollforming:

The rollformed body must be round, and both edges shall be parallel to each other

Rollforming overlap: E.g. ø 65, min. 5 mm, max. 8 mm

Check following after all these settings:

Weld 10 cans and do not cut the copper wire:

Check the wire gaps (gap between tin flows) on the copper wire. Tolerance should be < 0.5 mm

Measure each wire elongation, and compare them. Tolerance should be < 0.5 mm

Apply slightly more lacquer on outer side seam. Please follow therefor point 7.2 (Adjustment of the lacquer quantity) in the provided instruction manual for the ORC.

As a last precaution, check the viscosity of your lacquer by using the DIN 4 cup supplied. Recommended viscosity: 20–25 seconds. Depending on type of lacquer used, add corresponding thinner / water in order to achieve required viscosity.

Reference for thickness of the welding seam is related to thickness of material (this value is variable, depending on the overlap of the welding seam, material as hardness and tin coating, welding pressure, welding current and welding frequency).

Empty the water tank. On 2-circuit cooling unit only cold water tank has to be emptied.

Blow off one by one each cooling circuit in the welder. This allows to empty each circuit separately. If your welder has a 2-circuit cooling system only the circuit for the lower and upper weld roll has to be emptied.

Change the filter cartridge and clean the filter housing inside.

Fill the tank with water only, open main valve Y14, and run the system for at least one hour to flush rests of old emulsion out.

Empty the water tank again and clean again if necessary.

Fill the water tank with water (or distilled water if requested), and mix the PowerRoll™ coolant H1 in with 8 percent.

We recommend following maintenance procedures:

Change the filter cartridge monthly.

Change the cooling emulsion yearly. Use the PowerRoll™ cooling system cleaner at any time you change the emulsion.

NOTE: In case you have to replace the converter, make sure you load the default parameter setting. All the latest models, do have the parameter setting in the electrical scheme – if you do not have the parameter, contact Can Man by filling out a ticket in the support section on our website.

Possible cause:
The upper pendulum roller might be not leveled properly. When regrooving the upper disc for example 0.50 mm in diameter, the height of the pendulum rollerhead must be reduced 0.25 mm. This can be done by the M10 screw on the back side.

Your cooling system has to be checked and / or one or more circuits need to be cleaned.

Explanation:
If the temperature difference exceeds a certain value, mechanical mis-alignments may occur which can affect the welding geometry. Obviously it is not the same when a welder is cold (start of production) and hot (after up to1h of production).

Measure the overlap by reducing the welding current until the sheet edges can be broken apart to check, where the overlap is incorrect. NOTE: Machines with a PACEMAKER™ do have a „overlap check“ in the menu!

Check the blank cutting.

Check the condition to the nose piece (even maybe the Z-bar).

Check the „clearance“ of the calibration crown roller (also called hour glass or diabolo rollers), with special attention to the upper ones.

Check the position of the exit conveyor (weld a can without the conveyor and see the difference).

Check whether the idler wheel in front of the lower welding roll is in correct position, or whether the circlip is missing (Xplane only)!

Remove welding pressure and check if deviation of upper (outer) rollerhead (in most machines the pendulum rollerhead) is working properly (free of any mechanical friction or resistance)!

Follow 1. and check „copper belts“ (the flexible power conductors between the rollerhead and the upper bus bar) and that they are not give mechanical resistance (counterforce) to the welding pressure.

Following 1. and make sure that the „lift“ of the upper rollhead is not disabling the welding pressure to be fully obtained to the lower welding roll. This can happen if the both welding roller diam. are smaller than allowed.

Finally check, ideally with a „tension spring balance“, the actual welding force (usually it should be within 40–45 daN)

Adjust the rollformer (roller shaft clearance and spring pressure) according to the manual.

Control if there is a high difference in the tin plate hardness, by rollforming 10 bodies without welding. Put them on the floor in line and compare the difference in the rollforming overlap.

Check if the destacking process is going well. Make sure the tin plate is guided tight, and the separating air is positioned well.

Control the timing of the tin plate transport in between two transport fingers.

Make sure that the guidance channel is properly adjusted. The intersection to the precalibration of the calibration crown is most important.

Check the position of each (inside and outside!) transport finger compared to rollformed canbody.

Check the offset of each finger pair itself. Move the canbody slowly forward (X1 and X6 by slow mode function) and observe eventual shaking of the canbody until the welding point.

If a third finger exists: The third finger must be 0.5 mm behind the upper main pusher fingers!

Reset the calibration crown completely. Make sure that each precalibration roller is turning easily! If needed lubricate their shafts slightly and clean the roller afterwards. Make sure that these rollers are as close as possible to each other!

Measure the speed of the flat belt in the calibration crown:
The speed must be absolutely identical with the copper wire speed!

Measure the overtravel: Short can heights shall have 1 mm overtravel.

The center of the diabolo roller (equal to the center of calibration crown) shall be 1–2 mm before the welding center.

Wait around 10min before you do anything on the wiring of the pacemaker! The capacitors need that time to discharge!!!

Disconnect both welding cables from Pacemaker.

Measure the resistant of both cable to earth. If the value is very low maybe the transformer primary side have short circuit to earth or the cables are damaged and make some contact to earth. If it looks ok (endless or very high resistant) go to point 5.

Take the welding copper wire completely out of welder.

Control that pendulum roller head is lift up. Put a carton or another insulating material between both welding rollers to make sure that you don’t have any contact between the rollers.

Connect an external cable 230VAC (phase and neutral) to the welding cables, which you have removed on pacemaker before. Use for this external supply a 10A fuse breaker to protect the supply in case of a short circuit of welding transformer. (Take a look to picture on point 3)

Before you switch on the external supply check again:
– Wire removed?
– Pendelum rollerhead lift up and isolation between welding rollers?

Now switch on the external supply. If the 10A fuse breaker does not trip it is a good sign and it doesn’t look like short circuit of welding transformer.

To control the output of welding transformer you can measure the voltage between the welding rolls (VAC). The measured voltage is depending on the type of welding transformer. If you change the transformer step this value has also to change. Check the output voltage of each step. Don’t worry if you measure only around 5VAC, the output voltage of welding transformer is a low voltage.

Before you change the transformer step switch off first the external supply!!!

Report all steps, new or different settings, old and new production parameters (can size, cpm, weld speed, weld current, weld frequency, current wave-form and transformer step) for an easier overview and follow-up!

Open a new ticket and add your document!
Note on which tin-plate parameters (thickness, hardness, tin coating inside / outside, rolling direction, BA or CA, supplier, printed or not) such faults occur, and on which tinplates not!

Are all tin-plate parameter clear and noted: Thickness, hardness, tin coating in and outside, rolling direction, BA or CA, supplier, printed or not

Can-bodies must be correctly rollformed:

Not conical and best roundness must be reached!

Overlap of both tin-plates edges:

ø52 ~ 5mm

ø99 ~ 15mm

ø153 ~ 30mm

ø284 ~ 60mm

The copper wire must be correct profiled and the surface not damaged:

The width of the profiled copper wire shall always be 0.05 mm smaller than the profile-groove in the weld rollers!

Measure the width of the profiled copper wire within around half a meter on several position, and note the variations. Maximum difference of 0.05 mm are allowed. If you measure more, check the concentricity of the profiling rings.

Change the copper wire profiling rings or idler/guide wheels if the surface of the copper wire shows a damage!

Both weld rolls must be regrooved after its regular groove life-span:

To avoid unexpected heavy weld faults it is recommended to implement the total piece-counter and the regrooving interval into the production order!

Total piece counter at production start at 28 mio welded can bodies, upper weld disc has been regrooved at 25 mio, therefore to be regrooved now! Lower weld roll regrooved at 27.5 mio, therefore to be regrooved at 29.5 mio.

After every regrooving weld roll and / or z-bar must be repositioned: Use the correct to reset the lower weld roll and/or nose-piece, and the upper welding roller!

The z-bar must be clean in and outside – and not worn -, calibration crown must be clean, and are all pre-calibration rollers shall turning easily:

A dirty z-bar may not be well insulated, therefore the risk of wear is higher and the weld current is flowing over z-bar and tin-plate to the weld center!

Note: The insulation of the secondary circuit should be controlled yearly!

The welded overlap must be correct, and on begin and end within allowed tolerance:

Correct welded overlap depending on z-bar:

Z-bar of 0.4 mm results in a welded overlap of 0.5 – 0.6 mm

Z-bar of 0.6 mm results in a welded overlap of 0.7 – 0.8 mm

Z-bar of 0.8 mm results in a welded overlap of 0.9 – 1.0 mm

If the overlap is not correct, adjust until overlap is correct:

Reset the calibration crown if needed with the mandrel. The diabolo-rollers should not have any radial-play!

Adjust the overlap according manual.

Once the overlap has been set, double check and set the can gap. Increasing the overlap will reduce the can gap, decreasing the overlap will increase the can gap.

Weld around 5 cans and measure the gap between the tin-layers. A good can gap measures between 1.5 – 3.0 mm. Any variation should be within 0.5 – 1.0 mm.

The weld current frequency must fit:

Welders with a static frequeny inverter should have a welding spot length between 0.6 – 1.2 mm.

A welder without static frequency inverter should be operated between 8 – 12 m/min. Reducing the welding speed does decrease the welding spot length.

The welding spot lenght should always be as long as possible (by reducing the frequency) to reduce energy and heat in the welding seam and in the welder to a minimum.

Main target must be a flexible and smooth welding seam!

The main weld current must be set correct!

How to do:

Reduce weld current until cold weld zones appear. Tear-off test must be done at an angle of 30 – 45°, means try to pull-off the top tin plate edge. To be done from each side. Note the weld current value!

Increase weld current until hot weld appears. Tear-off test must be done at an angle of 0°, means pull-off the seam only and find out when the seam starts to become fragile. Note the weld current value!

Add 2/3 of the weld current difference between cold and hot weld seam to the cold weld seam value, and start the production!

Set beginning and end time and beginning and end current!

Note: If the welder is running with triangle wave-form, make sure the duty-cycle is between 80 – 90%. If the welder is running with sine wave-form, make sure the right transformer step has been choosen! Contact us if you are not sure.

The seam-extrusion inside and outside must be equal!

If the seam extrusion is bigger inside, reduce the height of the calibration crown. If the seam extrusion is bigger outside, increase the height of the calibration crown.

The shape or roundness of the can-body is not so important as a correct seam-extrusion!

The seam extrusion inside depend on the inner weld roll diameter as well: The diameter difference of upper and lower weld roll should be as small as possible.

Checklist to avoid micro leaksMicro leaks can occur within the seam and beside the seam – especially on cold-formed areas like necking, beading, flanging or seaming -, even if all above mentioned basic parameters & settings seems to be correct.
Micro leaks can have various sources: Wrong settings on the welder, tin-plate parameters which support such faults, worn or wrong machineries in the downline, or tin-plate parameters which do not fit to beader, necker, flanger and seamer.

For a better visual understanding put the faulty-can bodies in a water bath, and inspect the leaking area by a microscope. Store the pictures if possible!

Make sure that necker, flanger, beader and seamer are in good conditon, and do not stress the weld seam more than needed.

For further information check the manuals (check the tin-plate specifications range) or contact the supplier!

Try to weld different tin-plates to understand which tin-plate parameter can be produced without such faults.

Rolling-direction parallel to weld seam can increase the occurence of micro-leaks!

Micro-leaks in and near the seam can be reduced by changing the energy in each welding spot:

Reduce the welding frequency within the possible range (see point 13. in above checklist), and set the main weld current again (see point 14. in above checklist). The production cycle (cpm) must probably be reduced to reach a good weld seam. Produce a certain number of cans and test them.

Increase the welding frequency within the possible range, and set the current again. Produce a certain number of cans and test them.

Reduce the welding pressure to max 45 kg / daN, and set the main weld current again (see point 14. in above checklist). Produce a certain number of cans and test them.

Reduce the welded overlap by around 0.10 mm, and set the main weld current (see point 14. in above checklist). Produce a certain number of cans and test them.

If above listed does not help, some theoretically wrong settings could help:

Increase the can gap to have completely different welded begin and end. Produce a certain number of cans and test them, and set back if it didn’t helped!

Set a slight can-body offset, to bring the current different into the tin-plate. Produce a certain number of cans and test them, and set back if it didn’t helped!